US5832630A - Bladder and method of making the same - Google Patents

Bladder and method of making the same Download PDF

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Publication number
US5832630A
US5832630A US08/095,476 US9547693A US5832630A US 5832630 A US5832630 A US 5832630A US 9547693 A US9547693 A US 9547693A US 5832630 A US5832630 A US 5832630A
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United States
Prior art keywords
chambers
section
bladder
chamber
fluid
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Expired - Lifetime
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US08/095,476
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English (en)
Inventor
Daniel R. Potter
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Nike Inc
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Nike Inc
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Priority to US08/095,476 priority Critical patent/US5832630A/en
Priority to US09/186,183 priority patent/US6258421B1/en
Application granted granted Critical
Publication of US5832630A publication Critical patent/US5832630A/en
Priority to US09/722,285 priority patent/US6463612B1/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B13/00—Soles; Sole-and-heel integral units
    • A43B13/14—Soles; Sole-and-heel integral units characterised by the constructive form
    • A43B13/18—Resilient soles
    • A43B13/20—Pneumatic soles filled with a compressible fluid, e.g. air, gas
    • A43B13/206—Pneumatic soles filled with a compressible fluid, e.g. air, gas provided with tubes or pipes or tubular shaped cushioning members
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B13/00—Soles; Sole-and-heel integral units
    • A43B13/14—Soles; Sole-and-heel integral units characterised by the constructive form
    • A43B13/18—Resilient soles
    • A43B13/20—Pneumatic soles filled with a compressible fluid, e.g. air, gas
    • A43B13/203—Pneumatic soles filled with a compressible fluid, e.g. air, gas provided with a pump or valve
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B17/00—Insoles for insertion, e.g. footbeds or inlays, for attachment to the shoe after the upper has been joined
    • A43B17/02—Insoles for insertion, e.g. footbeds or inlays, for attachment to the shoe after the upper has been joined wedge-like or resilient
    • A43B17/03—Insoles for insertion, e.g. footbeds or inlays, for attachment to the shoe after the upper has been joined wedge-like or resilient filled with a gas, e.g. air
    • A43B17/035—Insoles for insertion, e.g. footbeds or inlays, for attachment to the shoe after the upper has been joined wedge-like or resilient filled with a gas, e.g. air provided with a pump or valve
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D22/00—Producing hollow articles
    • B29D22/02—Inflatable articles

Definitions

  • the present invention pertains to a bladder, having particular usefulness in the sole of a shoe, and a method for making the same.
  • Bladders have long been used in shoes as a cushion to increase shoe comfort, enhance foot support, reduce the risk of injury and other deleterious effects, and decrease fatigue.
  • the bladders are comprised of elastomeric materials which are shaped to define at least one pressurized pocket or chamber.
  • a bladder will actually define many chambers arranged in a pattern designed to achieve one or more of the above-stated objectives.
  • the chambers may be pressurized with a number of different mediums, such as air, various gases, water, or other liquids.
  • bladders have been constructed with a single chamber that extends over the entire area of the sole.
  • U.S. Pat. No. 2,080,469 to Gilbert entitled "Pneumatic Foot Support.”
  • bladders have included a number of chambers fluidly interconnected with one another. Examples of these types of bladders are disclosed in U.S. Pat. No. 4,183,156 to Rudy, entitled "Insole Construction For Articles of Footwear," and U.S. Pat. No.
  • bladders have been developed wherein the chambers are fluidly connected by restricted openings. Examples of these bladders are illustrated in U.S. Pat. No. 4,217,705 to Donzis, entitled “Self-contained Fluid Pressure Foot Support Device,” U.S. Pat. No. 4,129,951 to Petrosky, entitled “Air Cushion Shoe Base.” and U.S. Pat. No. 1,304,915 to Spinney, entitled “Pneumatic Insole.” These bladders, however, have tended to either be ineffective in overcoming the deficiencies of the non-restricted bladders or have been too expensive to manufacture.
  • Another shoe bladder manufactured by Etonic also includes a plurality of discrete chambers which lack fluid interconnection.
  • the chambers are, however, all formed at ambient pressure. This construction obviates the need to individually pressurize each chamber and thus results in less manufacturing costs. However, the use of chambers pressurized above ambient pressure is not possible. As a result, the versatility and potential gain from using the bladder is reduced.
  • each independent chamber must be individually pressurized. As can be readily appreciated, this process is not suitable for mass production, particularly in bladders having a significant number of chambers.
  • a bladder in accordance with the present invention is particularly useful in the sole of a shoe.
  • the bladder includes a plurality of chambers which are strategically arranged under specific areas of the plantar surface.
  • the chambers are pressurized to a certain internal pressure. Nevertheless, because the chambers define differing volumes of pressurized fluid, each of the chambers are capable of providing a unique resistance. This capacity enables the bladders to provide the desired support and cushion to any particular portion of the foot.
  • the bladder may be specially adapted to accommodate a particular activity.
  • a bladder with these characteristics can be fabricated quickly, easily, and at a low cost.
  • the method involves selectively forming a number of chambers with an elastomeric material, such that each chamber is in fluid communication with the others. Thereafter, the interior of the product is supplied with an amount of fluid, so that the chambers are all pressurized at the same desired level. The fluid communication is then sealed so that each of the chambers is separated from the other chambers.
  • certain portions of the bladder can be pressurized to different levels.
  • a first set of chambers are formed in fluid communication with each other; and a separate second set of chambers are formed in fluid communication with each other.
  • the first set is not in fluid communication with the second set.
  • the practice of either aspect of the inventive process facilitates the manufacture of a bladder having the above-described desirable characteristics in a manner which eliminates the difficulties experienced in the past.
  • a bladder having independent chambers that each provide a unique resistance can be made without having to individually pressurize each chamber. Further, the process is quick, easy, and economical.
  • FIG. 1 is a top plan view of a bladder of the present invention
  • FIG. 1a is a cross-sectional view taken along line 1a--1a in FIG. 1;
  • FIG. 2 is a top plan view of a bladder of the present invention at an interim stage of its fabrication
  • FIG. 2a is a cross-sectional view taken along line 2a--2a in FIG. 2;
  • FIG. 3 is a top plan view of a second embodiment of a bladder of the present invention.
  • FIG. 3a is a cross-sectional view taken along line 3a--3a in FIG. 3;
  • FIG. 4 is a cross-sectional view of the bladder shown in FIG. 1a contained within a midsole of a shoe;
  • FIG. 5 is a top plan view of a third embodiment of the present invention.
  • FIG. 6 is a top plan view of the third embodiment at an interim stage of its fabrication
  • FIG. 7 is a top plan view of a fourth embodiment of the present invention at an interim stage in its fabrication
  • FIG. 8 is a top plan view of a fifth embodiment of the present invention at an interim stage of its fabrication
  • FIG. 8a is a cross-sectional view taken along line 8a--8a in FIG. 8;
  • FIG. 8b is a cross-sectional view taken along line 8b--8b in FIG. 8.
  • a bladder 10 is a thin, elastomeric member defining a plurality of chambers or pockets 12. The chambers are pressurized to provide a resilient support.
  • Bladder 10 is particularly adapted for use in the midsole of the shoe, but could be included in other parts of the sole or have applicability in other fields of endeavor.
  • bladder 10 would preferably be encapsulated in an elastomeric foam 11 (FIG. 4). As is well known in the art, the foam need not fully encapsulate the bladder.
  • the bladder can be used to form the entire midsole or sole member.
  • bladder 10 is composed of a resilient, plastic material such as a cast or extruded ester base polyurethane film having a shore "A" hardness of 80 to 95 (e.g., Tetra Plastics TPW-250) which is inflated with hexafluorethane (e.g., Dupont F-116) or sulfur hexafluoride.
  • a resilient, plastic material such as a cast or extruded ester base polyurethane film having a shore "A" hardness of 80 to 95 (e.g., Tetra Plastics TPW-250) which is inflated with hexafluorethane (e.g., Dupont F-116) or sulfur hexafluoride.
  • hexafluorethane e.g., Dupont F-116
  • the bladders can also be fabricated by blow molding or vacuum forming techniques.
  • bladder 10 defines a forefoot support 14, a heel support 16, and a medial segment 18 interconnecting the two supports.
  • Chambers 12 each define a support portion 13 and a channel portion 15.
  • the support portions 13 are raised to provide a resilient resistance force for an individuals foot.
  • the channel portions 15 are relatively narrow in comparison to support portions 13, and are provided to facilitate the unique manufacturing process described below.
  • Forefoot and heel supports 14, 16 are comprised primarily of support portions 13 so that a cushioned support is provided under the plantar areas receiving the greatest impact pressure during use of the shoe.
  • Channel portions 15, while extending partially into the forefoot and heel supports 14, 16, are concentrated in medial segment 18.
  • the support portions 13 are arranged parallel to one another in a lateral direction across the sole to provide a suitable flexibility in the forefront sole portion and to apportion the cushioned resistance as desired. Nonetheless, different chamber arrangements could be used.
  • forefoot portion 14 includes chambers 12a-g.
  • Chambers 12a-g are of varying sizes, with the chambers nearer to the front (e.g., chamber 12a) defining a larger volume than those closer to medial segment 18 (e.g., chamber 12g).
  • all of the chambers 12a-g are pressurized to the same level.
  • the chambers with smaller volumes will provide a firmer support than the chambers with larger volumes, because the movement of a side wall defining a smaller chamber will involve a greater percentage of the volume of air being displaced than the same movement in a larger chamber.
  • chamber 12g will provide a firmer support than chamber 12a.
  • Channel portions 15a-g of chambers 12a-g in general, extend rearwardly from support portions 13a-g to a seal 20 located transversely across medial segment 18.
  • Channel portions 15 are essential to the unique manufacturing process described below.
  • channel portions 15 are provided along the sides of forefoot portion 14, so that the needed cushioned support is not taken from the central portions of the sole where it is most needed.
  • channel portions 15 for adjacent chambers 12 are placed on opposite sides of the sole. Of course, other arrangements could be used.
  • void chambers 22 are defined adjacent the more rearward chambers 12e-g.
  • a void chamber 22 is a chamber that has not been pressurized. Void chambers 22 exist because of the need to limit the volume of chambers 12e-g to provide a certain firmness in these portions of the bladder. Nevertheless, void spaces are not essential to the present invention and could be eliminated. In a midsole usage (FIG. 4) the resilient foam 11 would fill in the void space and provide ample support to the user's foot.
  • heel support 16 includes a row of chambers 12h-j.
  • three chambers 12h-j are provided.
  • the support portions 13h-j of these chambers are arranged parallel to one another in a generally longitudinal direction across the sole to ensure that all three chambers provide cushioned support for all impacts to the user's heel. Nonetheless, as with the forefoot portion, different chamber arrangements could be used.
  • each chamber 12h-j includes a channel portion 15 which extends from the support portion 13 to seal 20.
  • chambers 12h-j provide different resistance forces in the support of the heel. For example, the smaller chamber 12h will provide a firmer resistance than the larger chambers 12i or 12j. The firmer chamber 12h would act as a medial post in reducing pronation.
  • chambers 12h-j are pressurized to the same internal pressure as chambers 12a-g.
  • One preferred example of internal pressure for athletic footwear is 30 psi.
  • chambers 112h-j are pressurized to a different internal pressure than chambers 112a-g.
  • the pressure in the forefoot portion could be set at 35 psi, while the heel portion could be pressurized to 30 psi.
  • the particular pressure in each section though will depend on the intended activity and the size of the chambers, and could vary widely from the given examples.
  • two elastomeric sheets 24, 26 are preferably secured together to define the particular weld pattern illustrated in FIG. 2; that is, that the two opposed sheets 24, 26 are sealed together to define wall segments 28 arranged in a specific pattern (FIG. 2a).
  • the welding is preferably performed through the use of radio frequency welding, the process of which is well known. Of course, other methods of sealing the sheets could be used.
  • the bladder could also be made by blow molding or injection molding, the processes of which are also well known.
  • Common area 30 is defined at the location where seal 20 is formed (FIG. 2).
  • Common area 30 is fluidly coupled with all of the channel portions 15 of chambers 12a-j, so that all of the chambers are in fluid communication with one another.
  • An injection pocket 32 is provided to supply bladder 10 with a quantity of fluid.
  • Injection pocket 32 is in fluid communication with a pressurizing channel 34, which, in turn, is fluidly coupled to common area 30 (FIGS. 2 and 2a).
  • Chambers 12a-j therefore, are pressurized by inserting a needle (not shown) through one of the walls 24, 26 defining injection pocket 32, and injecting a pressurized fluid therein.
  • the pressurized fluid flows from pocket 32, through channel 34, into common area 30, through channel portions 15a-j and into the supporting portions 13a-j of all of the chambers 12a-j.
  • Walls 24, 26 are welded, or otherwise heat sealed, forming seal 20 (FIG. 1) to completely close common area 30 so that none of the chambers are in fluid communication with any of the other chambers. Although, it may in certain circumstances be desirable to provide interconnecting ports in other portions of the sidewalls of selected chambers. Once sealing weld 20 has been made, the needle is removed and channel 34 remains an uninflated void area. Hence, as can be readily appreciated, this unique independent chamber design can be fabricated by the novel process in an easy, quick, and economical manner.
  • bladder 110 defines a forefoot support 114, a heel support 116, and a medial segment 118.
  • the forefoot and heel supports 114, 116 each include a plurality of chambers 112.
  • forefoot support 114 includes chambers 112a-g and heel support 116 includes chambers 112h-j.
  • each chamber 112 includes a support portion 113 and a channel portion 115.
  • Void chambers 122 are also provided to achieve the desired firmness in chambers 112e-g and 112h.
  • forefoot support 114 and heel support 116 are divided by a sealing wall 117 across medial segment 118 prior to the supply of any pressurized fluid.
  • a common area 130, 131 is defined immediately adjacent each side of the sealing wall 117.
  • Common area 130 is in fluid communication with channels 115a-g, and common area 131 is in fluid communication with channels 115h-j.
  • a needle (not shown) is inserted into each injection pocket 132, 133.
  • two separate needles are preferably used, although one needle can be successively employed to inject fluid into each support 114, 116 if desired.
  • different pressure levels may be supplied into the two separated forefoot and heel supports 114, 116.
  • forefoot support 114 may be provided with a greater pressure (e.g., 35 psi) than the pressure (e.g., 30 psi) in heel support 116, to meet the specific resistance desired for the intended use of the shoe.
  • the heel support could be provided with a greater pressure than the forefoot support if desired.
  • seals 120, 121 function to close the fluid communication between the chambers so that each chamber is independent and separate from the remaining chambers. Once the seals have been formed the needles can be removed and injection pockets 132, 134 become uninflated void areas.
  • FIG. 5 which includes a significantly different weldment pattern 228 defining a plurality a chambers 212.
  • the chambers 212 each includes a support portion 213 and a channel portion 215.
  • the channel portions all fluidly interconnect the support portions 213 with a common area 230 (FIG. 6).
  • the bladder 310 is designed such that the channel portions are eliminated. More specifically, bladder 310 is formed by a weldment pattern 328 defining a plurality of chambers 312 comprised solely of support portions 315. The chambers are initially all fluidly interconnected via common area 330. Once the bladder has been fully pressurized, the common area 330 is sealed off to eliminate the fluid interconnection between the chambers (not shown).
  • FIG. 8 illustrates a bladder 410 which has been blow molded.
  • a plurality of chambers 412a-d are arranged into a unique pattern.
  • the chambers are fluidly interconnected by ports 414b-d.
  • ports 414b-d Of course other patterns of chambers and ports could be used.
  • this embodiment does not include a common area to which each chamber is joined. Rather, the chambers 412 are sequentially interconnected.
  • a needle is inserted into the side of pocket 431 to pressurize the chambers.
  • the chambers 412 are pressurized by the fluid passing sequentially through chambers 412a-d and ports 414a-d.
  • the ports 414a-d are sealed to separate the chambers from one another (not shown).
  • the sealing process is preferably formed in a single step by a specially configured die.
US08/095,476 1991-11-01 1993-07-23 Bladder and method of making the same Expired - Lifetime US5832630A (en)

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Application Number Priority Date Filing Date Title
US08/095,476 US5832630A (en) 1991-11-01 1993-07-23 Bladder and method of making the same
US09/186,183 US6258421B1 (en) 1993-07-23 1998-11-05 Bladder and method of making the same
US09/722,285 US6463612B1 (en) 1993-07-23 2000-11-28 Bladder and method of making the same

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US78670491A 1991-11-01 1991-11-01
US08/095,476 US5832630A (en) 1991-11-01 1993-07-23 Bladder and method of making the same

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US09/186,183 Division US6258421B1 (en) 1993-07-23 1998-11-05 Bladder and method of making the same

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EP (1) EP0543510B1 (de)
JP (1) JP3343269B2 (de)
CN (1) CN1047297C (de)
AU (1) AU681571B2 (de)
BR (1) BR9204192A (de)
CA (1) CA2080455C (de)
DE (1) DE69220759T2 (de)
MX (1) MX9206297A (de)
MY (1) MY118386A (de)
NZ (1) NZ244964A (de)
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EP0543510B1 (de) 1997-07-09
DE69220759T2 (de) 1998-01-15
DE69220759D1 (de) 1997-08-14
MY118386A (en) 2004-10-30
AU681571B2 (en) 1997-09-04
MX9206297A (es) 1993-08-01
BR9204192A (pt) 1993-05-11
CA2080455C (en) 1999-01-19
CA2080455A1 (en) 1993-05-02
EP0543510A1 (de) 1993-05-26
JPH05207905A (ja) 1993-08-20
TW214511B (de) 1993-10-11
JP3343269B2 (ja) 2002-11-11
CN1047297C (zh) 1999-12-15
AU2744592A (en) 1993-05-06
CN1074104A (zh) 1993-07-14
NZ244964A (en) 1995-03-28

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